US9556743B2 - Visual indicator of coating thickness - Google Patents

Visual indicator of coating thickness Download PDF

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Publication number
US9556743B2
US9556743B2 US14/789,676 US201514789676A US9556743B2 US 9556743 B2 US9556743 B2 US 9556743B2 US 201514789676 A US201514789676 A US 201514789676A US 9556743 B2 US9556743 B2 US 9556743B2
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Prior art keywords
layer
coating
abradable
microspheres
silicate
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US14/789,676
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US20160003092A1 (en
Inventor
Adam Lee Chamberlain
Andrew Joseph Lazur
Kang N. Lee
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Rolls Royce Corp
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Rolls Royce Corp
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Priority to US14/789,676 priority Critical patent/US9556743B2/en
Publication of US20160003092A1 publication Critical patent/US20160003092A1/en
Assigned to ROLLS-ROYCE CORPORATION reassignment ROLLS-ROYCE CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LAZUR, Andrew Joseph, CHAMBERLAIN, ADAM LEE, LEE, KANG N.
Priority to US15/381,825 priority patent/US10550711B2/en
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Publication of US9556743B2 publication Critical patent/US9556743B2/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
    • F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
    • F01D11/122—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with erodable or abradable material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • B05D5/061—Special surface effect
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/50—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on rare-earth compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/62222—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining ceramic coatings
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5024—Silicates
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    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C04B41/87—Ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/24—Deposition of silicon only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
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    • C—CHEMISTRY; METALLURGY
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • C—CHEMISTRY; METALLURGY
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    • C23C4/06—Metallic material
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    • C—CHEMISTRY; METALLURGY
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0616—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility
    • C04B2111/807—Luminescent or fluorescent materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • F05D2220/32—Application in turbines in gas turbines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • F05D2230/312—Layer deposition by plasma spraying
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00—Function
    • F05D2260/83—Testing, e.g. methods, components or tools therefor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/21—Oxide ceramics
    • F05D2300/211—Silica
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

  • the disclosure relates to coatings and techniques for determining a thickness of a coating.
  • high-temperature mechanical systems such as, for example, gas-turbine engines
  • gas-turbine engines must operate in severe environments.
  • the high-pressure turbine blades, vanes, blade tracks and blade shrouds exposed to hot gases in commercial aeronautical engines typically experience metal surface temperatures of about 1000° C., with short-term peaks as high as 1100° C.
  • Components of high-temperature mechanical systems may include a Ni- or Co-based superalloy substrate or a ceramic-based substrate, such as a ceramic matrix composite.
  • the substrate can be coated with a thermal barrier coating (TBC), an environmental barrier coating (EBC), or both to reduce surface temperatures.
  • TBC thermal barrier coating
  • EBC environmental barrier coating
  • the TBC, EBC, or both may allow use of the component at higher temperatures, which may improve efficiency of the high-temperature mechanical system.
  • gas turbine power and efficiency also may be improved by reducing the clearance between a gas turbine blade and a surrounding blade track or blade shroud.
  • One method of reducing the clearance between blade and track or shroud includes coating the blade track or blade shroud with an abradable coating. As the turbine blade rotates, the tip of the turbine blade may contact the abradable coating and wear away a portion of the coating to form a groove in the abradable coating corresponding to the path of the turbine blade. The intimate fit between the blade and abradable coating provides a seal, which may reduce or eliminate leakage of gas around the blade tip and increase the efficiency of the gas turbine engine by up to 5% in some cases.
  • the disclosure describes coatings that include at least one feature that facilitates visual determination of a thickness of the coating.
  • the coating may include a plurality of microspheres disposed at a predetermined depth of the coating.
  • the plurality of microspheres may define a distinct visual characteristic. By inspecting the coating and viewing at least one of the microspheres, the thickness of the coating may be estimated.
  • the plurality of microspheres may be embedded in a matrix material, and the distinct visual characteristic of the microspheres may be different than the visual characteristic of the matrix material.
  • the at least one feature may include at least one distinct layer in the coating system that includes a distinct visual characteristic, such as a color of the distinct layer. Similar to the microspheres, the at least one distinct layer may be disposed at a predetermined depth of the coating. By inspecting the coating and viewing the distinct layer, the remaining thickness of the coating may be estimated.
  • the abradable coating described herein includes at least one feature that may provide a simple visual indicator detectable during an on-wing inspection. This visual indicator may provide a simple and accurate indication of the ability of the abradable coating to provide proper sealing with the gas turbine blade, resulting in the system meeting efficiency targets.
  • the disclosure describes an article including a substrate and a coating on the substrate.
  • the coating may include at least one abradable layer.
  • the at least one abradable layer may include a matrix material a plurality of microspheres located within the at least one abradable layer at a predetermined depth from an outer surface of the coating.
  • the plurality of microspheres may define a visual characteristic distinct from the matrix material.
  • the plurality of microspheres may include at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • the disclosure describes an article including a substrate and a coating on the substrate.
  • the coating may include at least one abradable layer, a neodymium silicate layer, an erbium silicate layer, and a gadolinium silicate layer.
  • the neodymium silicate layer, the erbium silicate layer, and the gadolinium silicate layer may be adjacent to each other within the coating.
  • the disclosure describes a method including forming a coating on a substrate.
  • the coating may include at least one abradable layer.
  • the at least one abradable layer may include a matrix material and a plurality of microspheres located within the at least one abradable layer at a predetermined depth from an outer surface of the coating.
  • the plurality of microspheres may define a visual characteristic distinct from the matrix material.
  • the plurality of microspheres may include at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • the disclosure describes a method including forming a coating on a substrate.
  • the coating may include at least one abradable layer, a neodymium silicate layer, an erbium silicate layer, and a gadolinium silicate layer.
  • the neodymium silicate layer, the erbium silicate layer, and the gadolinium silicate layer may be adjacent to each other within the coating.
  • the disclosure describes a method including visually inspecting an abradable coating, wherein the coating comprises at least one abradable layer, and wherein the at least one abradable layer comprises a matrix material and a plurality of microspheres located within the at least one abradable layer at a predetermined depth from an outer surface of the coating.
  • the plurality of microspheres may define a visual characteristic distinct from the matrix material.
  • the plurality of microspheres may include at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • the method also may include determining a wear level of the abradable coating based at least in part on observation of at least one of the plurality of microspheres.
  • FIG. 1 is a conceptual cross-sectional diagram illustrating an example article that includes an example abradable coating including a plurality of microspheres including at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • FIG. 2 is a conceptual cross-sectional diagram illustrating another example article that includes an example abradable coating including a plurality of microspheres including at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • FIG. 3 is a conceptual cross-sectional diagram illustrating another example article that includes an example abradable coating including a plurality of microspheres including at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • FIG. 4 is a conceptual cross-sectional diagram illustrating another example article that includes an example abradable coating including a plurality of microspheres including at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • FIGS. 5A and 5B are conceptual diagrams illustrating example techniques for forming an abradable coating including a plurality of microspheres including at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide using air plasma spraying.
  • FIG. 6 is a flow diagram illustrating an example technique for forming an example abradable coating including a plurality of microspheres including at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • FIG. 7 is a conceptual cross-sectional diagram illustrating another example article that includes an example coating including a neodymium silicate layer, an erbium silicate layer, and a gadolinium silicate layer.
  • the present disclosure describes an abradable coating that includes at least one feature that facilitates visual determination of a thickness of the abradable coating.
  • the abradable coating may be formed on a component of a high temperature mechanical system, such as a gas turbine blade track or blade shroud. During operation of the gas turbine engine, the blade track or blade shroud is exposed to gases. Rubbing of a gas turbine engine blade against at least a portion of the abradable coating, erosion by the gases flowing past the abradable coating and contact with debris in the gases, or both, may remove portions of the abradable coating (e.g., cause the coating to wear).
  • the at least one feature may facilitate visual determination of a remaining thickness of the abradable coating.
  • the visual inspection may be performed at room temperature using visible wavelengths, UV wavelengths, or both. Additionally or alternatively, X-ray inspection or ultrasonic techniques may be used to detect a depth of the at least one feature below an outer surface of the abradable coating.
  • the abradable coating may include a plurality of layers (e.g., at least two abradable layers). At least one abradable layer of the plurality of abradable layers may include the at least one feature.
  • the abradable coating may be part of a coating system that includes at least one other layer.
  • the coating system may include at least one of an environmental barrier coating (EBC) layer or a bond layer.
  • EBC environmental barrier coating
  • the at least one feature that facilitates visual determination of a thickness of the abradable coating may include a plurality of microspheres that possess a distinctive visual characteristic under visual or UV-assisted inspection.
  • the abradable coating may include an abradable layer comprising a matrix material and the plurality of microspheres that define a visual characteristic distinct from the matrix material.
  • the matrix material may include at least one of a rare earth silicate, a stabilized zirconium oxide, a mullite, or barium-strontium-aluminum silicate (BSAS).
  • the plurality of microspheres may include at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • the rare earth silicate may include at least one of yttrium monosilicate (Y 2 SiO 5 ), yttrium disilicate (Y 2 Si 2 O 7 ), ytterbium monosilicate (Yb 2 SiO 5 ), ytterbium disilicate (Yb 2 Si 2 O 7 ), erbium monosilicate (Er 2 SiO 5 ), erbium disilicate (Er 2 Si 2 O 7 ), neodymium monosilicate (Nd 2 SiO 5 ), neodymium disilicate (Nd 2 Si 2 O 7 ), gadolinium monosilicate (Gd 2 SiO 5 ), or gadolinium disilicate (Gd 2 Si 2 O 7 ).
  • the rare earth oxide may include at least one of yttrium oxide (Y 2 O 3 ), ytterbium oxide (Yb 2 O 3 ), erbium oxide (ErO 3 ), neodymium oxide (Nd 2 O 3 ), or gadolinium oxide (Gd 2 O 3 ).
  • the at least one rare earth silicate, the at least one rare earth oxide, or the at least one rare earth silicate and rare earth oxide is present in the microspheres in a glass phase.
  • the at least one rare earth silicate, the at least one rare earth oxide, or the at least one rare earth silicate and the at least one rare earth oxide is present in the microspheres in a crystalline or semi-crystalline phase.
  • the microspheres may be substantially solid or may be hollow.
  • the plurality of microspheres may include a ceramic oxide and the at least one rare earth silicate, the at least one rare earth oxide, or the at least one rare earth silicate and at least one rare earth oxide.
  • the plurality of microspheres may include aluminum oxide doped with yttrium oxide, yttrium monosilicate, or yttrium disilicate; or may include yttrium-aluminum-garnet (YAG) doped with ytterbium oxide, ytterbium monosilicate, or ytterbium disilicate.
  • YAG yttrium-aluminum-garnet
  • At least some microspheres of the plurality of microspheres may include between about 0.1 atomic percent (at. %) and about 10 at. % of at least one element selected from the Lanthanide series of the periodic table, excluding ytterbium, e.g., lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), or lutetium (Lu).
  • ytterbium e.g., lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium
  • the at least one feature that facilitates visual determination of a thickness of the abradable coating may include a plurality of layers that possess respective distinct visual characteristics under visual or UV-assisted inspection.
  • the abradable coating may include a neodymium silicate layer, an erbium silicate layer, and a gadolinium silicate layer. Each of these three layers may appear differently (e.g., have different colors) under visual inspection.
  • the at least one feature may be used to determine a remaining thickness of the abradable coating.
  • the thickness of the abradable coating between the at least one feature and the immediately underlying layer e.g., EBC, bond layer, or substrate
  • the remaining thickness of the abradable coating at that location may be determined to be the thickness between the at least one feature and the immediately underlying layer.
  • this may facilitate at least one of determination of a remaining life of the abradable coating, determination of a size, depth, or both of damage to the abradable coating, and removal and repair of the abradable coating to maintain clearances between the abradable coating and a blade tip below a predetermined level to maintain a desired efficiency level of the gas turbine engine.
  • abradable coatings in other examples, the subject matter described herein may be applied to coatings of other types, such as abrasive coatings, thermal barrier coatings, environmental barrier coatings, self-lubricating coatings, or the like.
  • the layer structure and compositions may differ for these different applications, but layers including a plurality of microspheres in a matrix material or a plurality of layers with distinct visual characteristics may also be used in these other coating systems.
  • FIG. 1 is a conceptual diagram illustrating a cross-sectional view of an example article 10 that includes a substrate 12 coated with an abradable coating 14 .
  • abradable coating 14 includes a plurality of microspheres 18 and a matrix material 16 and is on a surface 19 of substrate 12 .
  • Article 10 may be a component of a high temperature mechanical system, such as, for example, a gas turbine engine or the like.
  • article 10 may be a turbine blade track or a turbine blade shroud.
  • Substrate 12 may include a metal alloy that includes silicon, a ceramic, or a ceramix matrix composite (CMC).
  • the ceramic may be substantially homogeneous.
  • a substrate 12 that includes a ceramic includes, for example, a Si-containing ceramic, such SiO 2 , silicon carbide (SiC) or silicon nitride (Si 3 N 4 ); Al 2 O 3 ; aluminosilicate (e.g., Al 2 SiO 5 ); or the like.
  • substrate 12 includes a metal alloy that includes Si, such as a molybdenum-silicon alloy (e.g., MoSi 2 ) or a niobium-silicon alloy (e.g., NbSi 2 ).
  • a metal alloy that includes Si such as a molybdenum-silicon alloy (e.g., MoSi 2 ) or a niobium-silicon alloy (e.g., NbSi 2 ).
  • substrate 12 includes a matrix material and a reinforcement material.
  • the matrix material includes a ceramic material, such as, for example, SiC, Si 3 N 4 , Al 2 O 3 , aluminosilicate, SiO 2 , or the like.
  • the CMC further includes a continuous or discontinuous reinforcement material.
  • the reinforcement material may include discontinuous whiskers, platelets, or particulates.
  • the reinforcement material may include a continuous monofilament or multifilament weave.
  • Article 10 further includes abradable coating 14 , which in the example of FIG. 1 is directly on surface 19 of substrate 12 .
  • Abradable coating 14 includes a plurality of microspheres 18 and a matrix material 16 .
  • Matrix material 16 may include at least one of a rare earth silicate, a stabilized zirconium oxide, mullite, or BSAS. In some examples, matrix material 16 includes at least one rare earth silicate.
  • the plurality of microspheres 18 may possess a visual characteristic that, under visual or UV-assisted inspection, is distinct from a visual characteristic of matrix material 16 .
  • the plurality of microspheres may include microspheres including at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide, and may include a composition different from the composition of matrix material 16 .
  • the at least one rare earth silicate, the at least one rare earth oxide, or the at least one rare earth silicate and the at least one rare earth oxide is present in the microspheres in a glass phase.
  • the at least one rare earth silicate, the at least one rare earth oxide, or the at least one rare earth silicate and the at least one rare earth oxide is present in the microspheres in a crystalline or semi-crystalline phase.
  • the rare earth silicate may include at least one of yttrium monosilicate (Y 2 SiO 5 ), yttrium disilicate (Y 2 Si 2 O 7 ), ytterbium monosilicate (Yb 2 SiO 5 ), ytterbium disilicate (Yb 2 Si 2 O 7 ), erbium monosilicate (Er 2 SiO 5 ), erbium disilicate (Er 2 Si 2 O 7 ), neodymium monosilicate (Nd 2 SiO 5 ), neodymium disilicate (Nd 2 Si 2 O 7 ), gadolinium monosilicate (Gd 2 SiO 5 ), or gadolinium disilicate (Gd 2 Si 2 O 7 ).
  • the rare earth oxide may include at least one of yttrium oxide (Y 2 O 3 ), ytterbium oxide (Yb 2 O 3 ), erbium oxide (ErO 3 ), neodymium oxide (Nd 2 O 3 ), or gadolinium oxide (Gd 2 O 3 ).
  • the plurality of microspheres 18 may be substantially solid or may be hollow.
  • the plurality of microspheres may include a ceramic oxide and the at least one rare earth silicate, the at least one rare earth oxide, or the at least one rare earth silicate and at least one rare earth oxide.
  • the plurality of microspheres may include aluminum oxide doped with yttrium oxide, yttrium monosilicate, or yttrium disilicate; or may include yttrium-aluminum-garnet (YAG) doped with ytterbium oxide, ytterbium monosilicate, or ytterbium disilicate.
  • YAG yttrium-aluminum-garnet
  • the plurality of microspheres 18 may fluoresce when exposed to UV radiation.
  • the plurality of microspheres 18 may include at least one of yttrium monosilicate (Y 2 SiO 5 ), yttrium disilicate (Y 2 Si 2 O 7 ), ytterbium monosilicate (Yb 2 SiO 5 ), or ytterbium disilicate (Yb 2 Si 2 O 7 ), all of which may fluoresce when exposed to UV radiation.
  • the plurality of microspheres 18 may possess a visual characteristic observable in the visible wavelengths that is different from a visual characteristic of matrix material 16 .
  • the color of the plurality of microspheres 18 may be different than the color of matrix materials.
  • the plurality of microspheres 18 may include at least one of erbium monosilicate (Er 2 SiO 5 ), erbium disilicate (Er 2 Si 2 O 7 ), neodymium monosilicate (Nd 2 SiO 5 ), neodymium disilicate (Nd 2 Si 2 O 7 ), gadolinium monosilicate (Gd 2 SiO 5 ), or gadolinium disilicate (Gd 2 Si 2 O 7 ).
  • erbium monosilicate Er 2 SiO 5
  • Er 2 Si 2 O 7 erbium disilicate
  • Nd 2 SiO 5 neodymium monosilicate
  • Nd 2 Si 2 O 7 neodymium disilicate
  • Gd 2 SiO 5 gadolinium monosilicate
  • Gd 2 Si 2 O 7 gadolinium disilicate
  • the plurality of microspheres 18 may include at least one dopant.
  • the at least one dopant may include at least one element from the Lanthanide series of the periodic table (excluding ytterbium).
  • the dopant may include at least one of lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), or lutetium (Lu).
  • the plurality of microspheres 18 may include between about 0.1 atomic percent (at. %) and about 10 at. % of the at least one dopant.
  • the plurality of microspheres 18 may include a mean diameter, median diameter, or the like, that is less than a thickness of the layer in which the plurality of microspheres 18 are located.
  • the plurality of microspheres 18 may have a mean diameter, median diameter, or the like, that is less than the thickness of abradable coating 14 (measured in the y-axis direction of FIG. 1 , where orthogonal x-y-z axes are shown for ease of description only).
  • the plurality of microspheres 18 may include a mean diameter, median diameter, or the like, that is less than 1000 micrometers (e.g., between 1 micrometer and 1000 micrometer), or less than about 100 micrometers (e.g., between 1 micrometer and 100 micrometer). In some examples, at least some microspheres of plurality of microspheres 18 may have a diameter less than a mean or median diameter of pores in abradable coating 14 .
  • the plurality of microspheres 18 may be located at a predetermined depth from an outer surface 17 of abradable coating 14 .
  • the predetermined depth may be a substantially consistent (e.g., consistent or nearly consistent) depth from surface 19 of substrate 12 .
  • the remaining thickness of abradable coating 14 at that location may be determined by observing the microspheres 18 and knowing the distance (e.g., in the y-axis direction of FIG. 1 ) between the plurality of microspheres 18 and surface 19 of substrate 12 .
  • this may facilitate at least one of determination of a remaining life of abradable coating 14 , determination of a size, depth, or both of damage to abradable coating 14 , and removal and repair of abradable coating 14 to maintain clearances between abradable coating 14 and substrate 12 below a predetermined level to maintain a desired efficiency level of the gas turbine engine.
  • abradable coating 14 defines a thickness, measured in a direction substantially normal to surface 19 of substrate 12 (e.g., measured in the y-axis direction of FIG. 1 ), between about 0.508 millimeters (about 0.02 inch) and about 2.032 mm (about 0.08 inch).
  • the thickness of abradable coating 14 may be selected to be sufficient to allow abrasion of a portion of abradable coating 14 by a gas turbine engine blade without the blade contacting substrate 12 .
  • Abradable coating 14 may be formed as a porous structure, which may facilitate abrasion of a portion of abradable coating 14 upon contact with a gas turbine engine blade or another moving component with which abradable coating 14 forms a seal.
  • abradable coating 14 includes porosity between about 25 vol. % and about 50 vol. %. In other examples, abradable coating 14 includes a porosity between about 35 vol. % and about 45 vol. %, or a porosity of about 40 vol. %.
  • Porosity of abradable coating 14 may be defined as a volume of pores or cracks in abradable coating 14 divided by a total volume of abradable coating 14 (including both the volume of material in abradable coating 14 and the volume of pores/cracks in abradable coating 14 ).
  • the porosity of abradable coating 14 may be controlled to vary throughout at least a portion of abradable coating 14 .
  • the porosity of abradable coating 14 may be controlled to be lower in a portion of abradable coating 14 closer to surface 19 of substrate 12 and greater in a portion of abradable coating 14 further from surface 19 of substrate 12 .
  • Abradable coating 14 may be formed over or formed directly on substrate 12 using, for example, a thermal spraying technique, such as, for example, air plasma spraying, as described in further detail with reference to FIGS. 5A and 5B .
  • Abradable coating 14 including matrix material 16 and plurality of microspheres 18 may facilitate visual inspection of a thickness of abradable coating 14 by including the plurality of microspheres 18 at a predetermined depth within the thickness of abradable coating 14 . In some examples, this visual inspection may occur at room temperature.
  • the plurality of microspheres 18 may possess a visual characteristic under visual or UV-assisted inspection (e.g., color or fluorescence) that is distinct from a visual characteristic of matrix material 16 .
  • this may facilitate at least one of determination of a remaining life of the abradable coating 14 , determination of a size, depth, or both of damage to abradable coating 14 , or removal and repair of the abradable coating to maintain clearances between the abradable coating 14 and a blade tip below a predetermined level to maintain a desired efficiency level of the gas turbine engine.
  • an abradable coating may include a plurality of layers, and at least one of the layers may be an abradable layer including a matrix material and a plurality of microspheres.
  • FIG. 2 is a conceptual cross-sectional diagram illustrating another example article 20 that includes an example abradable coating including a plurality of microspheres.
  • article 20 that includes a substrate 12 , an optional bond layer 22 on a surface 19 of substrate 12 , an optional environmental barrier coating (EBC) 24 on bond layer 22 , a first abradable layer 26 on EBC 24 , a second abradable layer 28 on first abradable layer 26 , and a third abradable layer 29 on second abradable layer 28 .
  • second abradable layer 28 includes a plurality of microspheres 18 and a matrix material 16 .
  • Article 20 may be similar to or substantially the same as article 10 of FIG. 1 , as described above.
  • article 20 may be a component of a high temperature mechanical system, including a gas turbine engine, a turbine blade track, a turbine blade shroud, a turbine blade or a turbine vane.
  • Substrate 12 may be similar to or substantially the same as substrate 12 of FIG. 1 , as described above.
  • substrate 12 may include a metal alloy that includes silicon, a ceramic, or a CMC.
  • article 20 may include a bond layer 22 on substrate 12 .
  • article 20 may not include a bond layer 16 .
  • Bond layer 16 may improve adhesion between substrate 12 and the layer overlying bond layer 16 (e.g., second abradable layer 28 in FIG. 2 ).
  • Bond layer 22 may include any useful material that improves adhesion between substrate 12 and an overlying layer.
  • bond layer 16 may include silicon. Regardless of the composition of bond layer 22 , bond layer 22 may have a thickness of between about 25.4 micrometers ( ⁇ m, about 0.001 inch) and about 254 ⁇ m (about 0.01 inch).
  • Bond layer 22 may be formed on substrate 12 using, for example, plasma spraying, physical vapor deposition (PVD), electron beam physical vapor deposition (EB-PVD), directed vapor deposition (DVD), chemical vapor deposition (CVD), cathodic arc deposition slurry process deposition, sol-gel process deposition, electrophoretic deposition, or the like.
  • PVD physical vapor deposition
  • EB-PVD electron beam physical vapor deposition
  • DVD directed vapor deposition
  • CVD chemical vapor deposition
  • cathodic arc deposition slurry process deposition sol-gel process deposition
  • electrophoretic deposition electrophoretic deposition
  • article 10 does not include bond layer 22 .
  • optional EBC 24 may be formed directly on substrate 12 .
  • Article 10 may not include bond layer 22 when the layer on substrate 12 and substrate 12 are sufficiently chemically and/or mechanically compatible.
  • article 10 may not include bond layer 22 .
  • the coefficients of thermal expansion of substrate 12 and EBC 24 are sufficiently similar, article 10 may not include bond layer 22 .
  • EBC 24 is on bond layer 22 and is optional. EBC 24 may reduce or substantially prevent attack of bond layer 22 and/or substrate 12 by chemical species present in the environment in which article 10 is utilized, e.g., in the intake gas or exhaust gas of a gas turbine engine.
  • EBC 24 may include a material that is resistant to oxidation or water vapor attack.
  • EBC 24 may include, for example, at least one of mullite; a glass ceramic such as barium strontium aluminosilicate (BaO—SrO—Al 2 O 3 -2SiO 2 ; BSAS), calcium aluminosilicate (CaAl 2 Si 2 O 8 ; CAS), cordierite (magnesium aluminosilicate), and lithium aluminosilicate; or a rare earth silicates (silicates of Lu, Yb, Tm, Er, Ho, Dy, Tb, Gd, Eu, Sm, Pm, Nd, Pr, Ce, La, Y, or Sc).
  • barium strontium aluminosilicate BaO—SrO—Al 2 O 3 -2SiO 2
  • BSAS barium strontium aluminosilicate
  • CaAl 2 Si 2 O 8 calcium aluminosilicate
  • cordierite magnesium aluminosilicate
  • the rare earth silicate may be a rare earth mono-silicate (RE 2 SiO 5 , where RE stands for “rare earth”) or a rare earth di-silicate (RE 2 Si 2 O 7 , where RE stands for “rare earth”).
  • EBC 24 is formed as a substantially non-porous layer, while in other examples, EBC 24 is formed as a layer that includes a plurality of cracks or pores.
  • EBC 24 may define a thickness, measured in a direction substantially normal to surface 19 of substrate 12 , between 25.4 ⁇ m (about 0.001 inch) and 508 ⁇ m (about 0.02 inch).
  • EBC 24 may be formed using, for example, CVD; PVD, including EB-PVD and DVD; plasma spraying or another thermal spraying process; or the like.
  • First abradable layer 26 is on optional EBC 24 .
  • first abradable layer 26 may be on bond layer 22 or substrate 12 (when both EBC 24 and bond layer 22 are omitted).
  • First abradable layer 26 may include a composition similar to or substantially the same (e.g., the same or nearly the same) as matrix material 16 of FIG. 1 .
  • first abradable layer 26 may include at least one of a rare earth silicate, a stabilized zirconium oxide, mullite, or BSAS.
  • First abradable layer 26 defines a thickness, measured in a direction substantially normal to surface 19 of substrate 12 , between about 25.4 ⁇ m (about 0.001 inch) and about 2.032 mm (about 0.08 inch).
  • First abradable layer 26 may be porous. In some examples, first abradable layer 26 includes porosity between about 25 vol. % and about 50 vol. %. In other examples, first abradable layer 26 includes porosity between about 35 vol. % and about 45 vol. %, or about 40 vol. %. In some examples, the porosity of first abradable layer 26 may be controlled to vary throughout at least a portion of first abradable layer 26 . For example, the porosity of abradable layer may be controlled to be lower in a portion of first abradable layer 26 closer to a surface of substrate 12 and greater in a portion of abradable layer further from the surface of substrate 12 .
  • Second abradable layer 28 is on first abradable layer 26 .
  • Second abradable layer 28 may be similar to or substantially the same (e.g., the same or nearly the same) as abradable coating 14 of FIG. 1 .
  • the composition of second abradable layer 28 may include plurality of microspheres 18 and matrix material 16 .
  • Plurality of microspheres 18 may be similar to or substantially the same (e.g., the same or nearly the same) as plurality of microspheres 18 of FIG. 1 .
  • matrix material 16 may be similar to or substantially the same (e.g., the same or nearly the same) as matrix material 16 of FIG. 1 .
  • Matrix material 16 may be same or different than the material in first abradable layer 26 .
  • Second abradable layer 28 defines a thickness, measured in a direction substantially normal to surface 19 of substrate 12 , between about 25.4 ⁇ m (about 0.001 inch) to about 2.032 mm (about 0.08 inch). Second abradable layer 28 may be formed as a porous structure. In some examples, second abradable layer 28 includes porosity between about 25 vol. % and about 50 vol. %. In other examples, second abradable layer 28 includes porosity between about 35 vol. % and about 45 vol. %, or about 40 vol. %. Similar to first abradable layer 26 , in some examples, the porosity of second abradable layer 28 may be controlled to vary throughout the thickness of second abradable layer 28 .
  • Third abradable layer 29 is on second abradable layer 28 .
  • the composition of third abradable layer 29 may be similar to or substantially the same as first abradable layer 26 , matrix material 16 in second abradable layer 28 , or both.
  • the composition of third abradable layer 29 may be different than the composition of at least one of first abradable layer 26 and matrix material 16 .
  • third abradable layer 29 may include at least one of a rare earth silicate, a stabilized zirconium oxide, mullite, or BSAS. Similar to first abradable layer 26 and second abradable layer 28 , third abradable layer 29 may define a thickness between about 25.4 ⁇ m (about 0.001 inch) to about 2.032 mm (about 0.08 inch).
  • Third abradable layer 29 also may be porous, and may have a porosity between about 25 vol. % and about 50 vol. %, between about 35 vol. % and about 45 vol. %, or about 40 vol. %.
  • Second abradable layer 28 and, more particularly, the plurality of microspheres 18 , may be positioned within coating 25 at a predetermined depth from outer surface 27 of coating 25 .
  • the predetermined depth may be determined based at least in part on a clearance between a blade tip and substrate 12 .
  • Second abradable layer 28 may facilitate visual determination of a thickness of second abradable layer 28 by including the plurality of microspheres 18 at a predetermined depth within the thickness of the coating 25 ,
  • the visual inspection of coating 25 may occur at room temperature.
  • the plurality of microspheres 18 may possess a visual characteristic under visual or UV-assisted inspection (e.g., color or fluorescence) that is distinct from a visual characteristic of matrix material 16 .
  • this may facilitate at least one of determination of a remaining life of coating 25 , determination of a size, depth, or both of damage to coating 25 , or removal and repair of the abradable coating to maintain clearances between coating 25 and a blade tip below a predetermined level to maintain a desired efficiency level of the gas turbine engine.
  • FIG. 3 is a conceptual diagram illustrating a cross-sectional view of an example article 30 that includes a substrate 12 , a bond layer 22 , an EBC 24 , a first abradable layer 26 , a second abradable layer 38 , and a third abradable layer 29 .
  • second abradable layer 38 includes a first plurality of microspheres 18 , a second plurality of microsphere 32 , and a matrix material 16 .
  • Article 30 of FIG. 3 may be similar to or substantially the same as article 20 illustrated in and described with respect to FIG. 2 , aside from the differences described herein. Unlike article 20 in FIG. 2 , article 30 of FIG. 3 includes a second abradable layer 38 that includes first plurality of microspheres 18 , second plurality of microspheres 32 , and matrix material 16 .
  • First plurality of microspheres 18 and second plurality of microspheres 32 may be similar to or substantially the same as plurality of microspheres 18 of FIG. 1 .
  • first plurality of microspheres 18 and second plurality of microspheres 32 may include at least one rare earth silicate, at least one rare earth oxide, or at least one rare earth silicate and at least one rare earth oxide.
  • the composition of first plurality of microspheres 18 may be different than the composition of second plurality of microspheres 32 .
  • first plurality of microspheres 18 may include a first rare earth silicate
  • second plurality of microspheres 32 may include a second, different rare earth silicate.
  • First plurality of microspheres 18 may be located at a first predetermined depth from an outer surface 36 of coating 34 . As shown in FIG. 3 , second plurality of microspheres 32 may be located at a second predetermined depth from outer surface 36 . The first and second predetermined depth are different from each other. First plurality of microspheres 18 may possess a visual characteristic under visual or UV-assisted inspection that is distinct from a visual characteristic of matrix material 16 and a visual characteristic of second plurality of microspheres 32 .
  • Coating 34 illustrated in FIG. 3 which includes first and second plurality of microspheres 18 , 32 facilitates visual determination of a thickness of second abradable layer 28 at two predetermined depths within the thickness of coating 34 .
  • the plurality of microspheres may be used to determine a remaining thickness of coating 34 .
  • a coating including microspheres located at multiple, different depths from outer surface 36 may facilitate more precise determination of the remaining thickness of coating 34 .
  • FIG. 3 illustrates an example in which second abradable layer 38 includes two types of microspheres 18 and 32 , in other examples, second abradable layer 38 may include more than two types of microspheres.
  • second abradable layer 38 may include a plurality of types of microspheres or at least two types of microspheres.
  • first plurality of microspheres 18 and second plurality of microspheres 32 are disposed within the same layer of coating 34 (second abradable layer 38 ). In other examples, first plurality of microspheres 18 and second plurality of microspheres 32 may be disposed in different layers of a coating.
  • FIG. 4 is a conceptual cross-sectional diagram illustrating another example article 40 that includes an example coating 48 including a plurality of microspheres.
  • Article 40 includes a substrate 12 , a bond layer 22 on substrate 12 , an EBC 24 on bond layer 22 , a first abradable layer 26 on EBC 24 , a second abradable layer 28 on first abradable layer 26 , a third abradable layer 44 on second abradable layer 44 , and a fourth abradable layer 29 on third abradable layer 44 .
  • Article 40 of FIG. 4 may be similar to or substantially the same as article 20 illustrated in and described with respect to FIG. 2 , aside from the differences described herein.
  • second abradable coating 28 includes a first plurality of microspheres 18 and a matrix material 16
  • third abradable layer 44 includes a second plurality of microspheres 42 and a matrix material 46 .
  • First plurality of microspheres 18 and second plurality of microspheres 42 may be similar to or substantially the same as plurality of microspheres 18 of FIG. 1 .
  • first plurality of microspheres 18 and second plurality of microspheres 42 may include at least one rare earth silicate.
  • the composition of first plurality of microspheres 18 may be different than the composition of second plurality of microspheres 42 .
  • first plurality of microspheres 18 may include a first rare earth silicate
  • second plurality of microspheres 42 may include a second, different rare earth silicate.
  • First plurality of microspheres 18 may be located in second abradable layer 28 at a first predetermined depth from an outer surface 50 of coating 48 . As shown in FIG.
  • second plurality of microspheres 42 may be located in third abradable layer 44 at a second predetermined depth from outer surface 50 .
  • the first and second predetermined depths are different from each other.
  • First plurality of microspheres 18 may possess a visual characteristic under visual or UV-assisted inspection that is distinct from a visual characteristic of matrix material 16 and second plurality of microspheres 42 may possess a visual characteristic that is distinct from a visual characteristic of matrix material 46 .
  • the visual characteristic of first plurality of microspheres 18 is different from the visual characteristic of second plurality of microspheres 42 .
  • Coating 48 illustrated in FIG. 4 which includes first and second plurality of microspheres 18 and 42 facilitates visual determination of a thickness of coating 48 at two predetermined depths within the thickness of coating 48 .
  • the plurality of microspheres may be used to determine a remaining thickness of the coating 48 .
  • a coating 48 including microspheres located at multiple, different depths from outer surface 50 may facilitate more precise determination of the remaining thickness of coating 48 .
  • FIG. 4 illustrates an example in which coating 48 includes two abradable layers 28 and 44 including a respective plurality of microspheres 18 and 42
  • coating 48 may include more than two layers including microspheres.
  • coating 48 may include a plurality of layers including microspheres or at least two layers including microspheres.
  • FIGS. 5A and 5B are conceptual diagrams illustrating example techniques for forming an abradable coating 14 including a plurality of microspheres 18 using air plasma spraying.
  • an article 10 includes an abradable coating 14 on surface 19 of substrate 12 .
  • Abradable coating 14 includes a plurality of microspheres 18 and a matrix material 16 .
  • the APS technique may utilize an APS gun 52 to spray plurality of microspheres 18 and matrix material 16 onto surface 19 of substrate 12 .
  • plurality of microspheres 18 and matrix material 16 in powder form may be mixed upstream of APS gun 52 , then sprayed onto abradable coating 14 .
  • the plurality of microspheres 18 may be deformed during the APS technique when passed through the APS gun 52 , e.g., due to softening or melting of the plurality of microspheres 18 .
  • the plurality of microspheres 18 and matrix material 16 may be mixed downstream of APS gun 52 , as shown in FIG. 5B .
  • FIG. 6 is a flow diagram illustrating an example technique for forming an example abradable coating including a plurality of microspheres.
  • the technique of FIG. 6 will be described with respect to article 20 of FIG. 2 .
  • the technique of FIG. 6 may be used to form other articles, and article 20 of FIG. 2 may be formed using other techniques.
  • the technique optionally includes forming bond layer 22 on substrate 12 ( 62 ).
  • Bond layer 22 may be formed on substrate 12 using plasma spraying; PVD, such as EB-PVD or DVD; CVD; cathodic arc deposition; slurry deposition; sol-gel deposition; electrophoretic deposition; or the like.
  • article 20 does not include bond layer 22
  • the technique of FIG. 6 does not include forming bond layer 22 on substrate 12 ( 62 ).
  • the technique also optionally includes forming EBC 24 on optional bond layer 22 (or substrate 12 if bond layer 22 is not present) ( 66 ).
  • EBC 24 may be formed using, for example, CVD; PVD, including EB-PVD and DVD; plasma spraying or another thermal spraying process; or the like.
  • article 20 does not include EBC 24
  • the technique of FIG. 6 does not include forming EBC 24 on bond layer 22 (or substrate 12 if bond layer 22 is not present) ( 62 ).
  • the technique of FIG. 6 also includes forming an optional first abradable layer 26 on EBC 24 ( 66 ).
  • first abradable layer 26 also may be formed on bond layer 22 or substrate 12 .
  • first abradable layer 26 may be formed using, for example, a thermal spraying technique, such as air plasma spraying or the like.
  • the technique of FIG. 6 also includes forming second abradable layer 28 on optional first abradable layer 26 ( 68 ).
  • second abradable layer 28 also may be formed on EBC 24 , bond layer 22 , or substrate 12 .
  • second abradable layer 28 may be formed using air plasma spraying, such as one of the technique illustrated with respect to FIGS. 5A and 5B .
  • plurality of microspheres 18 may be applied directly to the surface of the underlying layer (e.g., the surface of first abradable layer 26 ).
  • the plurality of microspheres 18 may be deposited using slurry deposition or application of an adhesive loaded with the plurality of microspheres 18 .
  • matrix material 16 is applied, e.g., using or slurry deposition, to form second abradable layer 28 .
  • third abradable layer 29 is formed on second abradable layer 28 ( 70 ).
  • third abradable layer 29 may be formed using, for example, a thermal spraying technique, such as air plasma spraying or the like.
  • a coating may include a plurality of layers within the coating that each have distinct visual characteristics compared to surrounding layers.
  • FIG. 7 is a conceptual cross-sectional diagram illustrating another example article that includes an example coating 88 including a neodymium silicate layer, an erbium silicate layer, and a gadolinium silicate layer.
  • Article 80 of FIG. 7 may be similar to or substantially the same as article 20 illustrated in and described with respect to FIG. 2 , aside from the differences described herein.
  • substrate 12 , bond layer 22 , EBC 24 , and first abradable layer 26 may be similar to or substantially the same as the corresponding structures described with respect to FIG. 2 .
  • Second abradable layer 92 may be similar to or substantially the same as third abradable layer 29 in FIG. 2 .
  • article 80 of FIG. 7 includes at least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 .
  • At least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 are between first abradable layer 26 and second abradable layer 92 .
  • FIG. 7 illustrates at least one gadolinium silicate layer 86 on at least one erbium silicate layer 84 and at least one erbium silicate layer 84 on at least one neodymium silicate layer 82 , in other examples, the order of these layers may be changed into any order.
  • coating 88 may include more than one of at least one neodymium silicate layer 82 , more than one of at least one erbium silicate layer 84 , or more than one of at least one gadolinium silicate layer 86 .
  • coating 88 may include multiple sets of at least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 .
  • coating 88 may include a different numbers of the at least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 (e.g., more neodymium silicate layers 82 than erbium silicate layers 84 and gadolinium silicate layers 86 , or the like).
  • At least one neodymium silicate layer 82 may include neodymium monosilicate or neodymium disilicate.
  • At least one erbium silicate layer 84 may include erbium monosilicate or erbium disilicate.
  • At least one gadolinium silicate layer 86 may include gadolinium monosilicate, or gadolinium disilicate.
  • the erbium monosilicate, erbium disilicate, neodymium monosilicate, neodymium disilicate, gadolinium monosilicate, or gadolinium disilicate may be doped with between about 0.1 at. % and about 10 at. % of an element selected from the Lanthanide series of the periodic table, excluding ytterbium.
  • At least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 may be located at respective a predetermined depths from an outer surface 90 of coating 88 .
  • at least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 each defines a thickness, measured in a direction substantially normal to surface 19 of substrate 12 , of between about 25.4 ⁇ m (about 0.001 inch) and about 2.032 mm (about 0.08 inch).
  • the thicknesses of at least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 may be the same or may be different.
  • the positions and thicknesses of at least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 may be determined from clearance requirements between the blade and seal segment (or blade track), such that the layers 82 , 84 , and 86 are located at a depth from surface 90 that approximate corresponds to an depth to which coating 88 is abraded during use.
  • At least one neodymium silicate layer 82 , at least one erbium silicate layer 84 , and at least one gadolinium silicate layer 86 may be applied by APS or by physical vapor deposition (e.g., EB-PVD, DVD, or the like).
  • Each of layers 82 , 84 , and 86 possesses a distinct visual characteristic (e.g., color) that is different than a visual characteristic of an adjacent layer.
  • Layers 82 , 84 , and 86 may facilitate visual inspection of a thickness of coating 88 by including the plurality of layers 82 , 84 , and 86 at a predetermined depth within the thickness of coating 88 . In some examples, this visual inspection may occur at room temperature.
  • Coating 88 which includes a plurality of layers 82 , 84 , and 86 (e.g., at least three) located at multiple, different depths from outer surface 88 , may facilitate more precise determination of the remaining thickness of coating 88 .
  • this may facilitate at least one of determination of a remaining life of the coating 88 , determination of a size, depth, or both of damage to coating 88 , or removal and repair of coating 88 to maintain clearances between coating 88 and a blade tip below a predetermined level to maintain a desired efficiency level of the gas turbine engine.
  • An article comprising: a substrate; and a coating on the substrate, wherein the coating comprises at least one abradable layer, wherein the at least one abradable layer comprises a matrix material and a plurality of microspheres located within the at least one abradable layer at a predetermined depth from an outer surface of the coating, wherein the plurality of microspheres define a visual characteristic distinct from the matrix material, and wherein the plurality of microspheres comprise at least one rare earth oxide, at least one rare earth silicate, or at least one rare earth oxide and at least one rare earth silicate.
  • Clause 2 The article of clause 1, wherein the coating further comprises an environmental barrier coating layer, wherein the environmental barrier coating layer comprises at least one rare earth silicate, and wherein the environmental barrier coating layer is between the substrate and the at least one abradable layer.
  • Clause 3 The article of clause 1 or 2, wherein the coating further comprises a bond layer between the substrate and the at least one abradable layer, wherein the bond layer comprises silicon.
  • Clause 4 The article of any one of clauses 1 to 3, wherein the at least one abradable layer comprises a first abradable layer and a second abradable layer, wherein the second abradable layer is on the first abradable layer, wherein the second abradable layer comprises the plurality of microspheres, and wherein the first abradable layer does not comprises microspheres.
  • Clause 5 The article of clause 4, wherein the at least one abradable layer further comprises a third abradable layer, wherein the third abradable layer is on the second abradable layer, and wherein the third abradable layer does not comprises microspheres.
  • Clause 6 The article of any one of clauses 1 to 3, wherein the plurality of microspheres comprise a first plurality of microspheres defining a first visual characteristic distinct from the matrix material, wherein the at least one abradable layer further comprises a second plurality of microspheres defining a second visual characteristic distinct from the matrix material and the first visual characteristic, wherein the first plurality of microspheres are located within the at least one abradable layer at a first predetermined depth from an outer surface of the abradable coating, and wherein the second plurality of microspheres are located within the at least one abradable layer at a second, different predetermined depth from an outer surface of the abradable coating.
  • Clause 7 The article of clause 6, wherein the first plurality of microspheres are located within the same abradable layer of the at least one abradable layer as the second plurality of microspheres.
  • Clause 8 The article of clause 6, wherein the first plurality of microspheres are located within a different abradable layer of the at least one abradable layer than the second plurality of microspheres.
  • Clause 9 The article of any one of clauses 1 to 8, wherein the plurality of microspheres comprises microspheres comprising at least one of yttrium monosilicate, yttrium disilicate, ytterbium monosilicate, ytterbium disilicate, erbium monosilicate, erbium disilicate, neodymium monosilicate, neodymium disilicate, gadolinium monosilicate, or gadolinium disilicate.
  • Clause 10 The article of clause 9, wherein the microspheres comprising the at least one of yttrium monosilicate, yttrium disilicate, ytterbium monosilicate, ytterbium disilicate, erbium monosilicate, erbium disilicate, neodymium monosilicate, neodymium disilicate, gadolinium monosilicate, or gadolinium disilicate further comprise between about 0.1 atomic percent (at. %) and about 10 at. % of an element selected from the Lanthanide series of the periodic table, excluding ytterbium.
  • An article comprising: a substrate; a coating on the substrate, wherein the coating comprises: at least one abradable layer; a neodymium silicate layer; an erbium silicate layer; and a gadolinium silicate layer, wherein the neodymium silicate layer, the erbium silicate layer, and the gadolinium silicate layer are adjacent to each other within the abradable coating.
  • Clause 12 The article of clause 11, wherein the at least one abradable layer comprises a first abradable layer and a second abradable layer, and wherein the neodymium silicate layer, the erbium silicate layer, and the gadolinium silicate layer are between the first abradable layer and the second abradable layer.
  • Clause 13 The article of clause 11 or 12, wherein the coating further comprises an environmental barrier coating layer, wherein the environmental barrier coating layer comprises at least one rare earth silicate, and wherein the environmental barrier coating layer is between the substrate and the at least one abradable layer.
  • Clause 14 The article of any one of clauses 11 to 13, wherein the coating further comprises a bond layer between the substrate and the at least one abradable layer, wherein the bond layer comprises silicon.
  • a method comprising: forming a coating on a substrate, wherein the coating comprises at least one abradable layer, wherein the at least one abradable layer comprises a matrix material and a plurality of microspheres located within the at least one abradable layer at a predetermined depth from an outer surface of the abradable coating, and wherein the plurality of microspheres define a visual characteristic distinct from the matrix material, and wherein the plurality of microspheres comprise at least one rare earth oxide, at least one rare earth silicate, or at least one rare earth oxide and at least one rare earth silicate.
  • Clause 16 The method of clause 15, wherein forming the coating on the substrate comprises air plasma spraying the at least one abradable layer over the substrate.
  • Clause 17 The method of clause 16, further comprising mixing the plurality of microspheres with the matrix material upstream of the air plasma spray gun.
  • Clause 18 The method of clause 16, further comprising mixing the plurality of microspheres with the matrix material downstream of the air plasma spray gun.
  • Clause 19 The method of clause 15, wherein forming the coating on the substrate comprises: applying the plurality of microspheres to a surface of a first abradable layer of the at least one abradable layer with an adhesive; and depositing a matrix material around the plurality of microspheres to form a second abradable layer comprising the matrix material and the plurality of microspheres.
  • Clause 20 The method of any one of clauses 15 to 19, wherein the matrix material comprises a rare earth silicate.
  • Clause 21 The method of any one of clauses 15 to 20, wherein the plurality of microspheres comprises microspheres comprising at least one of yttrium monosilicate, yttrium disilicate, ytterbium monosilicate, ytterbium disilicate, erbium monosilicate, erbium disilicate, neodymium monosilicate, neodymium disilicate, gadolinium monosilicate, or gadolinium disilicate.
  • Clause 22 The method of clause 21, wherein the microspheres comprising at least one of yttrium monosilicate, yttrium disilicate, ytterbium monosilicate, ytterbium disilicate, erbium monosilicate, erbium disilicate, neodymium monosilicate, neodymium disilicate, gadolinium monosilicate, or gadolinium disilicate further comprise between about 0.1 atomic percent (at. %) and about 10 at. % of an element selected from the Lanthanide series of the periodic table, excluding ytterbium.
  • Clause 23 A method comprising: forming a coating on a substrate, wherein the coating comprises: at least one abradable layer; at least one neodymium silicate layer; at least one erbium silicate layer; and at least one gadolinium silicate layer, wherein the at least one neodymium silicate layer, the at least one erbium silicate layer, and the at least one gadolinium silicate layer are adjacent to each other or staggered within the abradable coating.
  • Clause 24 The method of clause 23, the at least one abradable layer comprises a first abradable layer and a second abradable layer, and wherein forming the coating on the substrate comprises forming the at least one neodymium silicate layer, the at least one erbium silicate layer, and the at least one gadolinium silicate layer on the first abradable layer and forming the second abradable layer on the neodymium silicate layer, the erbium silicate layer, and the gadolinium silicate layer.
  • Clause 25 The method of clause 23 or 24, wherein the coating further comprises an environmental barrier coating layer, and wherein forming the coating on the substrate comprises forming the environmental barrier coating layer over the substrate and forming the at least one abradable layer over the environmental barrier coating layer.
  • Clause 26 The method of any one of clauses 23 to 25, wherein the coating further comprises a bond layer, wherein forming the coating on the substrate comprises forming the bond layer on the substrate, and wherein the bond layer comprises silicon.
  • a method comprising: visually inspecting a coating, wherein the coating comprises at least one abradable layer, wherein the at least one abradable layer comprises a matrix material and a plurality of microspheres located within the at least one abradable layer at a predetermined depth from an outer surface of the coating, and wherein the plurality of microspheres define a visual characteristic distinct from the matrix material, and wherein the plurality of microspheres comprise at least one rare earth oxide, at least one rare earth silicate, or at least one rare earth oxide and at least one rare earth silicate; and determining a wear level of the abradable coating based at least in part on observation of at least one of the plurality of microspheres.
  • Clause 28 The method of clause 27, wherein visually inspecting the coating is performed at room temperature.
  • the subject matter described herein may be applied to coatings of other types, such as abrasive coatings, thermal barrier coatings, environmental barrier coatings, self-lubricating coatings, or the like.
  • the layer structure and compositions may differ for these different applications, but layers including a plurality of microspheres in a matrix material or a plurality of layers with distinct visual characteristics may also be used in these other coating systems.

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US10544732B2 (en) * 2011-07-28 2020-01-28 Pratt & Whitney Canada Corp. Rotary internal combustion engine with removable subchamber insert
US10487847B2 (en) 2016-01-19 2019-11-26 Pratt & Whitney Canada Corp. Gas turbine engine blade casing
US20170362952A1 (en) * 2016-06-20 2017-12-21 United Technologies Corporation Air seal abrasive coating and method
US10544698B2 (en) * 2016-06-20 2020-01-28 United Technologies Corporation Air seal abrasive coating and method
US11480500B2 (en) * 2016-10-26 2022-10-25 Raytheon Technologies Corporation Method of inspecting component surface with marking media
US10428674B2 (en) * 2017-01-31 2019-10-01 Rolls-Royce North American Technologies Inc. Gas turbine engine features for tip clearance inspection
US11225879B2 (en) * 2019-01-09 2022-01-18 Safran Aircraft Engines Abradable turbomachine element provided with visual wear indicators
US11326469B2 (en) 2020-05-29 2022-05-10 Rolls-Royce Corporation CMCs with luminescence environmental barrier coatings

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EP2962844A2 (fr) 2016-01-06
EP2962844A3 (fr) 2016-04-13
US20160003092A1 (en) 2016-01-07
US10550711B2 (en) 2020-02-04

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